JP2013527027A - Cu-CHA / Fe-MFI mixed zeolite catalyst and method for treating NOX in gas stream - Google Patents

Abstract

The present invention relates to a catalyst, preferably a catalyst used for selective catalytic reduction (SCR), the catalyst comprising one or more zeolites of MFI structure type and one or more zeolites of BEA structure type, and MFI At least a portion of the one or more zeolites of the structural type and at least a portion of the one or more zeolites of the BEA structural type each contain iron (Fe). Furthermore, the present invention is an exhaust gas treatment system having the catalyst, and to a method of processing a gas stream containing NO _X using the above catalyst.
[Selection] Figure 1

Description

The present invention, catalysts preferably used in the selective catalytic reduction (SCR), an exhaust gas treatment system containing the catalyst, and to a method of processing a gas stream containing NO _X. In particular, the present invention relates to a method for reducing nitrogen oxides, and more particularly to selective reduction of nitrogen oxides with ammonia using a metal-promoted zeolite catalyst in the presence of oxygen.

  Emissions present in the exhaust gas of motor vehicles are divided into two groups. The term “first emissions” refers to polluted gases that are formed directly through the fuel combustion process in the engine or that are already present in the untreated emissions before passing through the exhaust gas treatment system. . The second emission means a polluted gas that can be produced as a by-product in the exhaust gas treatment system.

The exhaust gas of a lean burn engine contains the usual initial emissions of carbon monoxide CO, hydrocarbon HC and nitrogen oxides NO _x and relatively high oxides up to 15% by weight. In the case of diesel engines, in addition to the initial gaseous emissions, additional particulate emissions resulting from partial incomplete combustion in the cylinder (mainly composed of soot residue, with or without organic agglomerates) Exist).

  In diesel engines, the use of specific particulate filters is inevitable for the removal of particulate emissions. In addition, exhaust emission restrictions stipulated by laws in Europe and the United States require removal of nitrogen oxides from exhaust gases (denitrogenation action). Thus, while carbon monoxide and hydrocarbon contaminants from lean exhaust gases are easily detoxified via a suitable oxidation catalyst, the reduction of nitrogen oxides to nitrogen is an oxide of the exhaust gas stream. It is difficult because of the high content.

  Known methods for removing nitrogen oxides from exhaust gas include a first method using a nitrogen oxide storage catalyst and a second by selective catalytic reduction (SCR) using ammonia over a suitable catalyst, namely an SCR catalyst. There is a method.

  The nitrogen oxide storage catalyst provides a cleaning action on the nitrogen oxide stored mainly in the form of nitrate in the lean operation stage of the engine by the storage material of the storage catalyst. When the storage capacity of the NSC is exhausted, the catalyst is regenerated in the subsequent rich operation phase of the engine. This means that the nitrate produced in advance is decomposed, and the nitrogen oxide released again reacts with the reduced exhaust gas component via the storage catalyst to produce nitrogen, carbon dioxide and water.

  Because it is not easy to execute the rich operation stage in a diesel engine and auxiliary means such as post-injecting fuel into the exhaust gas line is often required to establish the rich exhaust gas conditions required for NSC regeneration, Other SCR methods are preferably used for the denitrification action of diesel motor vehicle exhaust. This method distinguishes between “active” and “passive” SCR methods according to engine design and exhaust system configuration. The “passive” SCR process uses a second emission of ammonia intentionally produced in the exhaust gas system as a reducing agent for denitrification.

For example, US Pat. No. 6,345,496 B1 discloses a method for cleaning engine exhaust gas. The lean and rich states of the air / fuel mixture are alternately repeated, so that the generated exhaust gas passes through an exhaust gas system having a catalyst that converts NO _x to NH ₃ on the inflow side only under the rich exhaust gas. To do. On the other hand, another catalyst arranged on the outflow side absorbs or occludes the lean exhaust gas NO _x and releases it under rich conditions. Thus, NO _X may give reacts with NH ₃ generated by the inflow side of the catalyst produced nitrogen. On the other hand, according to US Pat. No. 6,345,496, the NH ₃ adsorbent and the oxidation catalyst are arranged on the outflow side, occlude NH ₃ under a rich state, desorb under a lean state, and oxidize with oxygen. Generates nitrogen and water. Furthermore, similar methods are known. However, such as the use of nitrogen oxide storage catalysts, such a “passive” SCR method is one of the essential elements that are generally required for ammonia generation in situ as a reducing agent. There is a problem that it is a supply at.

  Compared to this, in the “active” SCR method, the reducing agent is metered into the exhaust gas line by means of an injection nozzle from an installation tank transported in the vehicle. Such reducing agents used are compounds that are easily decomposable to ammonia, such as urea or ammonium carbamate, apart from ammonia. Ammonia is supplied to the exhaust gas at least in a stoichiometric ratio with respect to nitrogen oxides. Since the driving state of the motor vehicle changes greatly, it is not easy to accurately measure and add ammonia. This sometimes leads to a large amount of ammonia breaking through the SCR catalyst. In order to suppress the second ammonia emission, the oxidation catalyst is usually arranged downstream of the SCR catalyst that oxidizes ammonia and reduces it to nitrogen. Such a catalyst is hereinafter referred to as an ammonia slip catalyst.

  In order to remove particulate emissions from diesel motor vehicle exhaust, certain diesel particulate filters with an oxidation catalyst-containing coating material are used to improve these properties. Such a coating reduces the activation energy used for the combustion of particulates by oxygen (soot combustion), thus lowering the soot ignition temperature of the filter and making the passive regeneration characteristics present in the monoxide present in the exhaust gas. Improve by oxidizing nitrogen and suppress breakthrough of hydrocarbon and carbon monoxide emissions.

Where legal emission standards require both denitrification and particulate removal from diesel motor vehicle exhaust, the disclosed techniques for removing individual pollutant gases are subject to corresponding conventional exhaust. Combined side by side in the gas system. For example, WO 99/39809 discloses an exhaust aftertreatment system in which an oxidation catalyst for oxidizing NO in NO _x to NO ₂ , a particulate filter, a measuring unit for a reducing agent, and an SCR catalyst are mutually connected. It is connected. In order to suppress the breakthrough of ammonia, it is generally required that an ammonia slip catalyst is provided downstream of the SCR catalyst, and it continues to the catalyst row on the outflow side of the SCR catalyst.

  In this regard, it is a known technique to promote certain reactions including synthetic and natural zeolites and their selective reduction of nitrogen oxides in the presence of oxygen. Zeolite is an aluminosilicate crystalline material having a fairly uniform pore size in the range of approximately 3-10 angstroms to diameter, depending on the type of zeolite and the type and amount of cations contained in the zeolite lattice It is.

  For example, European Patent Publication No. 1961933 relates to a diesel particulate filter for exhaust gas treatment having a filter body with an oxidation catalyst coating, an SCR-active coating, and an ammonia storage material. Among the materials used as the catalytically active component in the SCR reaction, the above document is a zeolite selected from beta zeolite, Y-zeolite, farjasite, modenite, and ZSM-5 which may be exchanged with iron or copper Mentions the use of a kind.

  On the other hand, European Patent Publication No. 1147801 relates to a method of reducing nitrogen oxides present in lean exhaust gas from an internal combustion engine by SCR using ammonia. The reduction catalyst preferably contains ZSM-5 exchanged with copper or iron. The above document relates to an SCR catalyst having a honeycomb substrate, which is coated with a ZSM-5 exchanged with iron.

  Part of European Patent Publication No. 2123614 relates to a honeycomb structure containing zeolites and an inorganic binder. In particular, the first zeolite included in the structure ion-exchanges metal ions including Cu, Mn, Ag, and V. Further included is a second zeolite exchanged with a metal comprising Fe, Ti and Co. Regarding the types of zeolites used for the first and second zeolites, these include zeolite beta, zeolite Y, ferrierite, ZSM-5 zeolite, modenite, faujasite, zeolite A, and zeolite L.

  U.S. Pat. No. 7,332,148 discloses stable aluminosilicate zeolites containing copper or iron, which stable zeolites are ZSM-5, ZSM-8, ZSM-11, ZSM-12, zeolite X, Includes zeolite Y, zeolite beta, modenite, and erionite.

  Finally, WO 2008/106519 discloses a zeolite having a CHA crystal structure and containing copper. This document discloses the use of such an ion exchange zeolite as an SCR catalyst.

  Thus, the prior art recognizes the utility of metal-promoted zeolite catalysts, including iron-promoted and copper-promoted zeolite catalysts, especially for the selective catalytic reduction of nitrogen oxides, especially with ammonia. About.

US Pat. No. 6,345,496 International Publication 99/39809 European Patent Publication No. 1961933 European Patent Publication No. 1147801 European Patent Publication No. 2123614 U.S. Pat. No. 7,332,148 International Publication 2008/106519

However, nowadays, stricter regulations regarding emissions, particularly exhaust emissions from motor vehicles, require improved catalysts and exhaust gas treatment systems that use such catalysts in treatment methods. As described above, the exhaust gas emission regulations in the European Union exhaust gas emission stage Euro 6 require reduction of NO _x emission of most passenger cars powered by a diesel engine. For this reason, the exhaust gas emission is New European Driving Cycle (NEDC) (also referred to as MVEG (Motor Vehicle Emission Group) test) defined in European Union Directive 70 / 220EEC. One means to meet this requirement includes an SCR catalyst technology device for the exhaust system of the vehicle in question.

  In contrast to the previous European driving cycle (ECE-15), the features of NEDC integrate the so-called extra-urban driving cycle, and the test reflects well the typical usage of vehicles in Europe. Yes. A typical discharge pattern is therefore associated with this. More specifically, in NEDC, the previous European driving cycle (ECE-15) is executed in the time of 0 to 800 seconds, whereas the extra-urban driving cycle is executed in the time up to 1200 seconds. Is done.

  The present invention has been made in view of the above problems, and an object of the present invention is an improved catalyst, particularly a catalyst used in selective catalytic reduction, for example, in practice with use of a motor vehicle performed in NEDC. It is an object of the present invention to provide a catalyst that is well suited to the emission status of the catalyst.

  In this regard, the present invention, outlined below, surprisingly provides improved catalysts. In particular, catalysts containing zeolites of both MFI and CHA structure types (MFI type zeolites contain iron and CHA type zeolites contain copper) are particularly improved when used in SCR applications. It was unexpectedly found to clearly show the properties of the catalyst.

Thus, the present invention relates to a catalyst, preferably a catalyst used for selective catalytic reduction (SCR), which catalyst comprises:
One or more MFI structure type zeolites;
One or more CHA structure type zeolites,
At least a part of the one or more zeolites of the MFI structure type includes iron (Fe), and at least a part of the one or more zeolites of the CHA structure type includes copper (Cu).

FIG. 1 shows the results of NEDC tests of catalyst components according to Example 1 and Comparative Example 2, in which the test time per unit second is plotted on the x-axis, and the NO _x emission amount per unit gram is plotted on the y-axis. Plotted. The background shows a pre-defined method of NEDC that has been tested over a period of time in terms of changes in the speed of a motor vehicle, defined as European Union Direct 70/220 / EEC. FIG. 2 is a graph showing the results of NO _x conversion rates in Example 1 and Comparative Examples 2 and 3 in the NEDC test.

Within the meaning of the present invention, the term “selective catalytic reduction”, abbreviated “SCR”, means any catalytic process involving the reaction of nitrogen oxides NO _x with a reducing agent. In particular, SCR means reduction, NO _X is reduced product, preferably is converted to N _2. With respect to the term “reducing agent”, this term means any suitable reducing agent for the SCR process, preferably any ammonia precursor such as ammonia and / or urea and / or ammonium carbamate. Urea is included in the ammonia precursor. More preferably, the term “reducing agent” means ammonia. However, the term “reducing agent” refers to, for example, motor vehicle fuel and / or motor vehicle exhaust gas, in particular hydrocarbons found in diesel fuel and / or diesel exhaust gas, and / or oxidized hydrocarbons, etc. The hydrocarbon derivative may be further contained.

  According to the invention, any possible zeolite of MFI or CHA structure type can be used if it exhibits typical structural properties of this type of structure type. With respect to one or more MFI-structured zeolites, these include, for example, ZSM-5, [AsSi-O] -MFI, [Fe-Si-O] -MFI, [Ga-Si-O] -MFI, AMS-1B, AZ-1, Bor-C, Boralite C, Ensilite, FZ-1, LZ-105, Monoclinic H-ZSM-5, Mutinaite, NU-4, NU-5, Silicalite, TS-1, TSZ, Contains one or more zeolites selected from the group consisting of TSZ-III, TZ-01, USC-4, USI-108, ZBH, ZKQ-TB, organic free ZSM-5, and mixtures of two or more thereof. . According to a preferred embodiment of the present invention, the one or more zeolites of MFI structure type comprise ZSM-5.

For one or more zeolites of the CHA structure type, these are chabazite, AIP, [Al-As-O] -CHA, [Co-Al-PO] -CHA, [Mg-Al-PO]. -CHA, [Si-O] -CHA, [Zn-As-O] -CHA, | Co | [Be-PO] -CHA, | Li-Na | [Al-Si-O] -CHAO-34. , CoAPO-44, CoAPO-47, DAF-5, anhydrous Na fluorite, GaPO-34, potassium fluorite, LZ-218, Linde R, MePO-47, MeAPO-47, Ni (data) ₂ -UT-6 , Phi, SAPO-34, SAPO-47, SSZ-13, SSZ-62, UiO-21, Wilhendersonite, ZK-14, ZYT-6, and mixtures of two or more thereof. Comprising one or more zeolites, which are. According to a preferred embodiment of the present invention, one or more zeolites of CHA structure type are chabazite, SSZ-13, LZ-218, Linde D, Linde R, Phi, ZK-14, and ZYT-6. And one or more zeolites selected from the group consisting of two or more of these, more preferably one or more zeolites of the CHA structure type including chabazite.

  As further described, according to an embodiment of the present invention, the one or more zeolites of the MFI structure type contain ZSM-5, and the one or more zeolites of the CHA structure type include chabazite, SSZ-13, Including one or more zeolites selected from the group consisting of LZ-218, Linde D, Linde R, Phi, ZK-14, and ZYT-6, and mixtures of two or more thereof, and even more preferably, ZSM- One or more zeolites of MFI structure type including 5, and one or more zeolites of CHA structure type including chabazite. According to a particularly preferred embodiment, the one or more zeolites of the MFI structure type are ZSM-5 and the one or more zeolites of the CHA structure type are chabazite.

  According to the present invention, at least some of the one or more MFI-type zeolites contain iron and at least some of the one or more CHA-structure type zeolites contain copper. With respect to the iron contained in at least a part of one or more MFI-type zeolites and the copper contained in at least a part of one or more CHA-type zeolites, the above metals can each be any conceivable embodiment and any conceivable. It can be contained in a state. Thus, according to the present invention, there is no particular limitation regarding the oxidation state of iron and copper contained in the catalyst and the method contained in the zeolite of each embodiment. However, preferably iron and / or copper, more preferably both iron and copper exhibit an oxidation state in the respective zeolite. Furthermore, iron and / or copper are contained on the surface of the zeolite and / or within the porous structure of the respective zeolite structure. Iron and / or copper are contained in the zeolite structure in addition to or alternatively to be included in the surface of the zeolite and / or in the porous structure of the respective zeolite structure. For example, isomorphous substitution. According to a preferred embodiment, the iron and / or copper is carried on the surface of the respective zeolite and / or the porous structure of the respective zeolite structure, more preferably the surface of the respective zeolite and the respective zeolite. It is supported both within the porous structure of the structure. According to a particularly preferred embodiment of the invention, both iron and copper are contained in at least a part of one or more zeolites of the MFI and CHA structure types in the oxidation state, respectively. It is supported on the surface of each zeolite, including that contained in the structure.

  According to the present invention, the catalyst contains one or more zeolites of the MFI structure type and one or more zeolites of the CHA structure type in any possible mass ratio. Preferably, the mass ratio of one or more zeolites of MFI structure type to one or more zeolites of CHA structure type is 1:10 to 10: 1, more preferably 1: 5 to 5: 1, more Preferably from 1: 2 to 2: 1, more preferably from 0.7: 1 to 1: 0.7, more preferably from 0.8: 1 to 1: 0.8, and even more preferably 0.8. 9: 1 to 1: 0.9.

  According to a particularly preferred embodiment of the present invention, the mass ratio of MFI type zeolite to CHA type zeolite is approximately 1: 1.

  According to the invention, it is preferred that each of the one or more zeolites of MFI structure type and / or one or more zeolites of CHA structure type contains both Al and Si in their structure. More preferably, the MFI structure type zeolites and the CHA structure type zeolites each contain both Al and Si in their structure. Thus, according to the present invention, it is more preferred that the one or more zeolites, and more preferably all of the zeolites, contain both Al and Si in their respective zeolite structures.

  With respect to embodiments of the invention in which one or more of the zeolites contain both Al and Si in their structure, the zeolites in principle exhibit any ratio of Al and Si. However, for embodiments of the invention in which one or more of the MFI structure type zeolites contain both Al and Si in their structure, the moles of silica relative to alumina in the one or more zeolites of the MFI structure type. The ratio (SAR) is preferably in the range of 5 to 150, more preferably 15 to 100, more preferably 20 to 50, more preferably 23 to 30 and even more preferably 25 to 25. 27 ranges. Furthermore, in an embodiment of the invention that contains both Al and Si in the structure of one or more zeolites of the CHA structure type, the SAR in the one or more zeolites of the CHA structure type is in the range of 5-100, More preferably, it is in the range of 10-70, more preferably in the range of 20-55, more preferably in the range of 25-35, and even more preferably in the range of 28-32. According to a particularly preferred embodiment of the present invention containing both Al and Si in the structure of one or more zeolites of both MFI and CHA structure types, in one or more zeolites of MFI structure type The SAR is in the range of 5 to 150, and the SAR in the one or more zeolites of the CHA structure type is in the range of 5 to 100, more preferably the SAR in the one or more zeolites of the MFI structure type is in the range of 15 to 100, and The SAR in the one or more zeolites of the CHA structure type is in the range of 10 to 70, more preferably the SAR in the one or more zeolites of the MFI structure type is in the range of 20 to 50, and the one or more zeolites of the CHA structure type SAR in the range of 20-55, more preferably in one or more zeolites of MFI structure type, SAR in the range of 23-30, and C The SAR in the one or more zeolites of the A structure type is in the range of 25 to 35, and even more preferably, the SAR in the one or more zeolites of the MFI structure type is in the range of 25 to 27, and the one or more zeolites of the CHA structure type The SAR in the class is preferably in the range of 28-32.

  Regarding the amount of iron contained in the MFI-type zeolite and the amount of copper contained in the CHA-type zeolite, according to the present invention, there is no particular limitation on the respective contents. However, according to the present invention, the amount of iron (Fe) in the one or more zeolites of the MFI structure type is in the range of 0.1 to 15% by mass based on the mass of the one or more zeolites of the MFI structure type. More preferably, the amount of iron is in the range of 0.5 to 10% by mass, more preferably in the range of 1.0 to 7.0% by mass, and more preferably 2%. A range of 0.5 to 5.5% by mass, more preferably a range of 3.5 to 4.2% by mass, and even more preferably a range of 3.7 to 4.0% by mass is preferable. Further, according to the present invention, the amount of copper (Cu) in the one or more zeolites of the CHA structure type is in the range of 0.05 to 15% by mass based on the mass of the one or more zeolites of the CHA structure type. More preferably, the amount of Cu is in the range of 0.1 to 10% by mass, more preferably 0.5 to 5.0% by mass, and more preferably 1.0 to 4.0%. It is in the range of mass%, more preferably 1.6-3.4 mass%, and even more preferably 1.8-3.2 mass%. According to a particularly preferred embodiment of the present invention, the amount of iron in the one or more zeolites of the MFI structure type is in the range of 0.1 to 15% by weight, and the amount of copper in the one or more zeolites of the CHA structure type. The amount is in the range of 0.1 to 10% by weight, more preferably the amount of iron in the one or more zeolites of the MFI structure type is in the range of 1.0 to 7.0% by weight, and one or more of the CHA structure type. The amount of copper in the zeolites in the range of 0.5 to 5.0% by weight, more preferably the amount of iron in the one or more zeolites of MFI structure type is in the range of 2.5 to 5.5% by weight. And the amount of copper in the one or more zeolites of the CHA structure type is in the range of 1.0 to 4.0% by weight, more preferably the amount of iron in the one or more zeolites of the MFI structure type is 3.5. In the range of ~ 4.2% by weight and one or more zeora of CHA structure type The amount of copper in the range of 1.6 to 3.4% by weight, even more preferably, the amount of iron in the one or more zeolites of MFI structure type is in the range of 3.7 to 4.0% by weight. And the amount of copper in the one or more zeolites of the CHA structure type is in the range of 1.8-3.2% by weight.

  According to the invention, the catalyst is supplied in any conceivable shape, for example in the form of a powder, granules or monolith. In this respect, it is particularly preferred that the catalyst further comprises a substrate on which one or more zeolites are applied. In general, the substrate is formed from a known material. For this reason, a porous material is used as the base material. In particular, cordierite, α-alumina, aluminosilicate, cordierite alumina, silicon carbide, aluminum titanate, silicon nitride, zirconia, mullite, zircon, zircon mullite, zircon silicate, silimanite, magnesium silicate, petalite, spodumene Ceramic and ceramic-like materials such as alumina silicon magnesium and zirconium silicon, porous flame retardant metals and their oxides are preferably used. According to the present invention, “flame retardant metal” means one or more metals selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W and Re. The substrate may also be formed from a ceramic fiber composition material. According to the invention, the substrate is preferably formed from cordierite, silicon carbide, and / or aluminum titanate, and more preferably cordierite and / or silicon carbide.

  Substrates useful for the catalyst of embodiments of the present invention are also made of metal and composed of one or more metals or alloys. Various shapes such as a corrugated sheet or a monolith shape can be adopted as the metal substrate. Suitable metal supports include heat resistant metals and metal alloys such as titanium and stainless steel, alloys in which iron is a substantial or major component. Such alloys contain one or more of nickel, chromium and / or aluminum, and the total amount of these metals is, for example, 10-25% by weight chromium, 3-8% by weight aluminum and 20% by weight. It is preferably at least 15% by mass of the alloy, such as nickel. The alloy also contains minor or trace amounts of one or more metals such as manganese, copper, vanadium, titanium, and the like. The surface or metal substrate is oxidized at a high temperature, for example 1000 ° C. or higher, improving the resistance of the alloy to corrosion due to the formation of an oxide layer on the surface of the substrate.

  Furthermore, the substrate according to the present invention may have any conceivable shape as long as it allows fluid to contact at least a portion of one or more zeolites of MFI and CHA structure types. Preferably, the substrate is a monolith, more preferably the monolith is a flow-through monolith. Suitable substrates contain any material typically used to prepare catalysts and usually have a ceramic or metal honeycomb structure. Thus, the monolithic substrate has narrow parallel gas channels extending from the inlet to the outlet at the surface of the substrate so that it is a channel open to the liquid flow (referred to as a honeycomb flow-through substrate). The flow path that is necessarily straight from the liquid inlet to the liquid outlet is one or more zeolites of the MFI and CHA structure types so that the gas flowing down the flow channel contacts one or more zeolites of the MFI and CHA structure types. Are demarcated by respective walls. The flow path of the monolithic substrate is a thin wall-like groove and has any suitable cross-sectional shape and size such as trapezoidal, rectangular, square, sinus, hexagonal, elliptical, or circular. Such a structure has up to 900 gas inlet openings (e.g. cells) per unit square inch of cross section, and according to the invention, the structure is preferably 50-600 units per unit square inch. , More preferably 300 to 500, and even more preferably 350 to 400 openings.

  Thus, according to a preferred embodiment of the present invention, the catalyst has a monolithic substrate, preferably a honeycomb substrate.

  According to a further preferred embodiment of the present invention, the substrate is formed of a wall flow monolith. In these embodiments, the substrate is preferably a honeycomb wall flow filter, a curved or packed fiber filter, an open cell foam, or a sintered metal filter, with a wall flow filter being particularly suitable. For equally suitable flow-through monoliths, useful wall flow substrates have a plurality of narrow and substantially parallel gas flow paths that extend along the axis of the substrate. Typically, each flow path is closed at one end of the base body, and the other flow paths are closed at the opposite end face. A particularly suitable wall flow substrate for use in the present invention comprises a thin porous walled honeycomb monolith that allows the liquid stream to flow down without causing an excessive increase in back pressure or pressure across the catalyst. The ceramic wall flow substrate used in the present invention is preferably formed of a material having a porosity of at least 40%, more preferably 40-70%, and has a substantial pore size of 5 microns, Preferably it has a pore size of 5 to 30 microns. More preferably, the substrate has a porosity of at least 50% and the substantial pore size is at least 10 microns.

  Thus, according to the present invention, the substrate suitably contained in the catalyst is selected from the group consisting of a flow-through substrate and a wall flow substrate, more preferably a cordierite flow-through substrate and a wall flow substrate, and carbonization. Selected from the group consisting of a silicon flow-through substrate and a wall flow substrate.

  In general, according to embodiments of the present invention further comprising a substrate, the zeolites are provided on the substrate in any conceivable shape, preferably in the form of one or more layers as a washcoat layer. Provided. In a preferred embodiment of the invention, the catalyst comprises a substrate and has two or more layers provided on the substrate, and the zeolites are applied to the two or more layers in any possible manner. Thus, the present invention has preferred embodiments, for example, zeolites contained in a single two or more layers, and embodiments such as zeolites contained in a single or more layers. However, the zeolites are preferably contained in a single layer regardless of the number of layers present in the substrate.

  Thus, according to a preferred embodiment of the present invention in which the catalyst comprises a substrate, it is more preferred that the catalyst has one or more layers, contained in a single layer or two or more separated layers. More preferred is a washcoat layer in which zeolites are applied to the substrate and the zeolites are preferably contained in a single layer.

  In a further embodiment of the invention having a substrate and two or more layers applied to the substrate, one or more of the above layers contain zeolites, and of the one or more layers containing zeolites, MFI and CHA There is no particular restriction on the distribution of one or more zeolites of the structural type. Thus, in principle, according to the present invention, for example, each of the layers containing zeolite contains MFI and CHA-type zeolites, respectively, or only the portion of the layer containing zeolites contains MFI and Contains both CHA-type zeolites. Furthermore, according to a further embodiment of the invention, the single layer does not contain both MFI and CHA type zeolites, which are contained in the separation layer of the catalyst. However, according to the invention itself, at least one of the layers of such an embodiment contains both MFI and CHA type zeolites, and even more preferably, the above implementation containing zeolites. Each of the two or more layers of the form contains both MFI and CHA type zeolites.

In principle, if an improved catalyst according to the present invention is obtained, each of the one or more zeolites of MFI and CHA structure type is present in the catalyst in any conceivable amount. Thus, both the one or more zeolites of the MFI structure type, the one or more zeolites of the CHA structure type, the one or more zeolites of the MFI structure type and the one or more zeolites of the CHA structure type are both 0 .1 to 5.0 g / in ³ respectively in the catalyst, and these loadings are preferably 0.7 to 2.0 g / in ³ , more preferably 1.0 to 1.g. 7g / in ^3, more preferably 1.15~1.55g / in ^3, more preferably 1.25~1.45g / in ^3, more preferably 1.32~1.38g / in ^3, Even more preferred is an amount of 1.34 to 1.36 g / in ³ . In particular, the respective loads of the MFI and CHA type zeolites are independent of each other and belong to the other structural type in the sense that a suitable loading can be applied to either the MFI type or CHA type zeolites. Each of the above-mentioned zeolite loadings is not particularly limited, and may be any loading amount or limited to various loads. Thus, in the present invention, for example, the loading amount of MFI type zeolites is 0.1 to 5.0 g / in ³ and the loading amount of CHA type zeolites is 1.34 to 1.36 g / in ³ . An embodiment, an embodiment in which the loading of MFI-type zeolite is 0.7 to 2.0 g / in ³ and a loading of CHA-type zeolite is 1.32 to 1.38 g / in ³ , An embodiment in which the load of MFI-type zeolite is 1.0 to 1.7 g / in ³ and the load of CHA-type zeolite is 1.25 to 1.45 g / in ³ , loadings 1.15~1.55g / in ³ a is and loading of CHA-type zeolites embodiment; 1.15~1.55g / in ^3, loading of the MFI-type zeolites 1. 25~1.45g / in ³ and is and CHA-type peptidase Embodiment loadings LIGHTS are 1.0~1.7g / in ^3, loading of the MFI-type zeolites are 1.32~1.38g / in ³ and load of the CHA type zeolites Is 0.7 to 2.0 g / in ³ , the load of MFI zeolite is 1.34 to 1.36 g / in ³ and the load of CHA zeolite is 0.1 to Including embodiments that are 5.0 g / in ³ .

  In addition to the catalyst described above, the present invention relates to an exhaust gas treatment system. In particular, the processing system of the present invention comprises an internal combustion engine, preferably a lean combustion engine, and more preferably a diesel engine. However, according to the present invention, a lean combustion gasoline engine can also be used in the above processing system.

  Furthermore, the treatment system according to the invention has an exhaust gas conduit in fluid communication with the internal combustion engine. In this regard, any conceivable conduit can be used provided that it can handle exhaust gases from the internal combustion engine, the conduit being the exhaust gas of the internal combustion engine in a temperature or a lean combustion engine, especially a diesel engine. Can sufficiently resist chemicals exposed in it. Within the spirit of the present invention, fluid transmission between the exhaust gas conduit and the internal combustion engine indicates that the treatment system provides a constant passage of exhaust gas from the engine to the conduit.

  According to the exhaust gas treatment system of the present invention, the catalyst is present in the exhaust gas conduit. In general, the catalyst can be connected to the exhaust gas conduit in any manner that can be envisaged, provided that it is present in the exhaust gas conduit in the sense that the exhaust gas can be contacted with the exhaust gas by passing through the conduit. Can be provided. The catalyst is preferably applied on a substrate provided in an exhaust gas conduit as outlined herein, and the substrate is preferably a flow-through or wall-flow honeycomb substrate.

  Thus, the present invention also relates to an internal combustion engine and an exhaust gas treatment system having an exhaust gas conduit in fluid communication with the internal combustion engine, wherein the catalyst according to the present invention is present in the exhaust gas conduit and the internal combustion engine is preferably lean. A combustion engine, more preferably a diesel engine.

  Independently in this regard, the invention also relates to an embodiment in which the catalyst according to the invention is contained in an exhaust gas treatment system having an internal combustion engine and an exhaust gas conduit in fluid communication with the internal combustion engine. The internal combustion engine which is present in the gas conduit and is preferably a lean combustion engine, more preferably a diesel engine.

  According to a preferred embodiment of the invention, the exhaust gas treatment system further comprises means for introducing a reducing agent into the exhaust gas stream, which means are arranged upstream of the MFI / CHA zeolites according to the invention. ing. In particular, it is preferable that a means for introducing ammonia and / or urea into the exhaust gas conduit is provided. In this regard, any known means are provided and are particularly applicable to exhaust gas treatment systems operated with active SCR means that require direct introduction of the reducing agent as described above. According to a particularly preferred embodiment, the reducing agent, which is suitable ammonia and / or urea, is introduced by means of an injection nozzle provided in the exhaust gas conduit upstream of the inventive catalyst.

  Within the scope of the present invention, the exhaust gas treatment system may have any further elements for the effective treatment of exhaust gas. In particular, the system suitably comprises an oxidation catalyst or a catalyzed soot filter (CSF) or both an oxidation catalyst and a CSF. According to the above embodiment, the oxidation catalyst and / or CSF is present in the exhaust gas conduit.

  In the present invention, any suitable CSF is used when soot contained in the exhaust gas can be effectively oxidized. Because of this action, the CSF of the present invention preferably has a substrate coated with a washcoat layer containing one or more catalysts for burned deodorant soot and / or oxidant exhaust gas stream emissions. In general, soot-fired catalysts are known catalysts for soot combustion. For example, CSF is an oxidation catalyst for combustion of one or more high surface area flame retardant oxides (eg, alumina, silica, silica alumina, zirconia, and zirconia alumina) and / or unburned hydrocarbons and some particulate matter. (Eg ceria zirconia). However, the soot combustion catalyst is preferably an oxidation catalyst containing one or more noble metals, and the one or more noble metal catalysts are preferably one or more metals selected from the group consisting of platinum, palladium, and rhodium. Containing.

Optional in respect to the preferred oxidation catalyst containing exhaust gas treatment system in addition to or in CSF instead of CSF, unburned hydrocarbons contained in the exhaust gas, suitable for the oxidation of CO, and / or NO _X The oxidation catalyst is used. In particular, one or more noble metal catalysts, more preferably an oxidation catalyst comprising one or more noble metals selected from the group consisting of platinum, palladium, and rhodium are suitable. According to a particularly preferred embodiment of the invention, the internal combustion engine of the exhaust gas treatment system is a diesel engine and the oxidation catalyst is preferably a diesel oxidation catalyst. In particular, within the spirit of the present invention, “diesel oxidation catalyst” refers to any oxidation catalyst that is particularly well suited to diesel exhaust oxides, particularly with respect to the temperature and components of the diesel exhaust encountered in the process. means.

  According to a particularly preferred embodiment, the exhaust gas treatment system further contains CSF, and even more preferably contains both CSF and an oxidation catalyst. More preferably, the exhaust gas treatment system further contains CSF and a diesel oxidation catalyst.

  In principle, in an embodiment of an exhaust gas treatment system that further contains an oxidation catalyst and / or CSF, if the exhaust gas is to be effectively treated, the further elements can be in any order and in any arrangement. In the exhaust gas conduit. In particular, however, the presence and / or order and / or arrangement of the further elements mentioned above depend on the type and condition, in particular with regard to temperature and pressure, and on the average composition of the exhaust gas being processed. Thus, depending on the equipment of the exhaust gas treatment system, the present invention provides a preferred embodiment in which the oxidation catalyst and / or CSF is located upstream or downstream of the MFI / CHA zeolite catalyst of the present invention, and oxidation. Having a preferred embodiment with both catalyst and CSF, the oxidation catalyst is located upstream and the CSF is located downstream, or conversely, the CSF is located upstream and the oxidation catalyst is downstream Be placed. According to a particularly preferred embodiment of the present invention, the oxidation catalyst and / or CSF is arranged upstream of the inventive MFI / CHA zeolite catalyst, more preferably the exhaust gas treatment system comprises an MFI according to the invention. / Contains both oxidation catalyst and CSF upstream from the CHA zeolite catalyst. Within the meaning of the present invention, “upstream” and “downstream” relate to the flow direction of the exhaust gas through the exhaust gas conduit in fluid communication with the internal combustion engine.

  Thus, the present invention also relates to an exhaust gas treatment system as defined above, wherein the exhaust gas treatment system further comprises an oxidation catalyst and / or a catalyzed soot filter (CSF), the oxidation catalyst and / or Or the CSF is preferably located upstream from the MFI / CHA zeolite catalyst according to the invention, and the oxidation catalyst is a diesel oxidation catalyst (DOC) with the internal combustion engine being a diesel engine.

  Furthermore, as outlined above, the exhaust gas treatment system preferably further comprises means for introducing a reducing agent into the exhaust gas conduit, which means are located upstream from the inventive MFI / CHA zeolite catalyst. The In particular, the means make it possible to introduce a reducing agent containing ammonia and / or urea into the exhaust gas conduit. Accordingly, the present invention is in addition to or in addition to having an oxidation catalyst and / or a catalyzed soot filter (CSF), each preferably disposed upstream from the MFI / CHA zeolite catalyst according to the invention. With respect to an exhaust gas treatment system having an oxidation catalyst that becomes a diesel oxidation catalyst (DOC) when the engine is a diesel engine, the system is a means for introducing a reducing agent suitably containing ammonia and / or urea into the exhaust gas conduit And this means is arranged upstream of the MFI / CHA zeolite catalyst according to the invention.

  According to a further preferred embodiment of the present invention, the exhaust gas treatment system comprises an ammonia slip catalyst that is arranged downstream of the MFI / CHA zeolite catalyst and oxidizes excess ammonia and / or urea that did not react with the SCR. Also have. With respect to suitable ammonia slip catalysts, known catalysts may be placed in the exhaust gas conduit as long as the catalyst effectively oxidizes the excess ammonia and / or urea. In particular, the preferred embodiment described above comprises an exhaust gas treatment system according to the invention having means for introducing a reducing agent into an exhaust gas conduit as defined above.

In addition to the exhaust gas treatment system having a catalyst and the above catalyst, the present invention relates to a method of treating a gas stream containing NO _X. In general, in the process of the present invention, any suitable gas stream containing NO _x is suitable for both its state and components to be treated when contacted with the MFI / CHA zeolite catalyst according to the present invention. If so, it can be processed. At least some preferred the process includes a selective catalytic reduction of at least a portion of the NO _X containing the gas. For this purpose, the gas stream used in the process according to the invention preferably contains at least one reducing agent. The reducing agent is preferably any ammonia precursor, such as ammonia and / or urea and / or ammonium carbamate, which is preferably contained in the ammonia precursor. However, according to a further embodiment of the method of the invention, the gas stream used is hydrocarbon and / or, for example, motor vehicle fuel and / or motor vehicle exhaust gas, in particular diesel fuel and / or exhaust gas. Hydrocarbon derivatives such as oxygen-containing hydrocarbons present in The reducing agent may be contained in the gas treated by the method according to the invention in addition to ammonia, or according to another embodiment, contained in the gas instead of ammonia. May be. However, according to the invention, it is preferred that the gas contains ammonia and / or urea as a reducing agent, particularly for the treatment of exhaust gas emissions via SCR.

Thus, the present invention relates to a method for treating a gas stream containing NO _x as defined in the present invention, wherein the gas stream contains ammonia and / or urea.

With respect to the content of the reducing agent in the gas stream, the reducing agent is ammonia if it is reduced by the SCR when at least a portion of the NO _{x in} the gas comes into contact with the MFI / CHA zeolite catalyst of the present invention. It is preferable to contain urea and / or urea, and this point is not particularly limited. However, the content of the reducing agent, it is preferable that not derived from considerable to the amount of the reducing agent required for maximum conversion of the NO _X by the catalyst. In this regard, the maximum conversion of the NO _X indicates the maximum amount of the NO _X that can be converted by the SCR at the time of the method according to the invention. That is, the maximum conversion depends on the actual state and conditions of both the gas and the catalyst to be treated by contact with the reducing agent, in particular on the reducing agent content, and preferably contained in the reducing agent. Depending on the amount of ammonia and / or urea to be produced. Thus, the maximum conversion of NO _x directly reflects the maximum amount of reducing agent. The reducing agent is ammonia and / or urea reacts with NO _X at the point in the SCR process is preferred.

According to a preferred embodiment of the present invention, the gas stream used in the process according to the invention, an exhaust gas stream containing NO _X are preferred. In this regard, for processes that lead to such exhaust gas streams, if suitable for treatment with the MFI / CHA zeolite catalyst of the present invention or if processed into a gas stream suitable for treatment with such catalysts. There is no particular limitation. According to the inventive method, the exhaust gas stream is preferably an exhaust gas stream originating from an internal combustion engine, more preferably an exhaust gas stream originating from a lean combustion engine. According to a particularly preferred embodiment, the exhaust gas stream is a diesel engine exhaust gas stream.

  In the process according to the invention, the gas stream is treated in contact with the inventive MFI / CHA zeolite catalyst. This contact is effected by covering the catalyst with a gas stream or passing the gas stream through the catalyst. However, such contact may be achieved by passing over the catalyst according to the invention. According to a preferred embodiment, the catalyst containing the flow-through substrate is preferably covered with a gas stream or the gas stream is passed through the catalyst. In this case, the catalyst preferably has a wall flow substrate. However, when using a wall flow substrate, the catalyst is covered with at least a portion of the gas stream based on the process conditions and the specific form and shape of the catalyst. In a particularly preferred embodiment of the method according to the invention, the catalyst used in the method according to the invention contains both a wall flow honeycomb substrate and a flow-through honeycomb substrate.

The present invention thus relates to a method for treating a gas stream containing NO _{x, in} which the gas stream covers or is passed over the MFI / CHA zeolite catalyst according to the invention. The gas stream is preferably an exhaust gas stream, more preferably an exhaust gas stream originating from an internal combustion engine, more preferably a diesel exhaust gas stream.

In the method according to the invention, the amount of NO _x contained in the gas stream is not particularly limited, but the amount of NO _x in the gas stream used in the method according to the invention is based on the total mass of the exhaust gas. Is preferably 10% by mass or less, more preferably 1% by mass or less, more preferably 0.1% by mass or less, more preferably 0.05% by mass or less, and more preferably 0.03% by mass. Hereinafter, it is still more preferably 0.01% by mass or less.

For certain component of the NO _X traces contained in the gas stream to be treated by the method according to the invention, there is no limitation as to the kind and content of a particular nitrogen oxide gas NO _X contained in the gas stream . However, according to a particular embodiment of the present invention, the content of NO ₂ to the total content of the NO _X is 80 wt%, or preferably less 100 weight% of the NO _X, more preferably, NO The content of ₂ is in the range of 5 to 70% by mass, more preferably in the range of 10 to 60% by mass, more preferably in the range of 15 to 55% by mass, and even more preferably in the range of 20 to 50% by mass. is there.

  In general, the components of the gas stream used in the inventive method as defined in this application precede the use of the components in the inventive method, in particular the contact between the catalyst and the component. Preferably, however, the component represents a component of the gas stream immediately before contacting the catalyst. That is, it is a component immediately before the start of the treatment by catalytic chemical conversion.

Thus, the present invention also relates to a process for the treatment of a gas stream containing NO _x as defined in this application, which treatment is carried out before the contact of the catalyst with the gas stream and contains NO ₂ . The amount is 80% by mass or less than the standard of 100% by mass of NO _x , more preferably the NO ₂ content is in the range of 5 to 70% by mass, more preferably 10 to 60% by mass, more preferably 15%. It is -55 mass%, More preferably, it is the range of 20-50 mass%.

  The catalyst according to the present invention can be easily prepared by a known method. A typical method will be described below. The general meaning of “washcoat” as used herein is a thin and well known technique known in the art that is used as a substrate carrier material, such as a honeycomb carrier member, which preferably has sufficient pores to provide a passage for the treated gas. A catalyst or other material with an adhesive coating.

  Some zeolitic components of the catalyst can be applied to the substrate as a mixture of one or more components in a continuous step in a manner that will be apparent to those skilled in the catalyst art. A typical process for the production of the catalyst according to the invention consists of coating each of at least one zeolite of the MFI structure type and of at least one zeolite of the CHA structure type on the walls of a particularly suitable flow-through or wall-flow honeycomb substrate. Or it is giving as a washcoat layer. According to some preferred embodiments of the present invention, the zeolites are provided as a single washcoat on the substrate.

  However, the catalyst according to the present invention is preferably prepared using at least one binder, and a binder that can be arbitrarily envisaged in the catalyst field, particularly in the automobile SCR catalyst field, is used. In this respect, the silica alumina binder is preferably used, for example, for the preparation of the catalyst according to the invention, which binder is applied with one or more zeolite components, preferably the zeolite component in one or more coatings on the substrate. More preferably, it is applied together with one or more washcoat layer zeolite components.

  In order to prepare the catalyst according to the invention, one or possibly more washcoat layers are each processed into a slurry. Preferred is an aqueous slurry. The substrate is immersed in each slurry to be applied to individual washcoats after excess slurry is removed to provide a thin coating of two or more slurries on the substrate walls. The coated substrate is dried and preferably calcined to provide a coating having adhesion of the respective components to the substrate walls. Thus, for example, after the initial washcoat layer has been applied on the substrate, and preferably after the coated substrate has been dried and / or calcined, the resulting coated substrate is the first wash. A further slurry is dipped to form a second washcoat layer over the coat layer. Again, the substrate is dried and / or calcined, finally coated with a third washcoat and subsequently dried and / or calcined again to provide the finished catalyst according to one embodiment of the invention. Is done. Regarding the drying, washing and calcination steps of the catalyst coated by this method, in particular with regard to the solvents and / or solutions used for washing the coated catalyst, the temperature, duration, used in the drying and calcination steps, And the atmosphere, respectively, are carried out by methods known in the catalyst field. For the calcination process, especially for use in the SCR, any temperature can be used provided that the process leads to the desired deformation of the catalyst without causing any significant or substantial degradation in catalyst stability. Can be used. Thus, in some cases, the calcination temperature does not exceed 700 ° C., preferably 650 ° C. or less, more preferably 600 ° C. or less, and even more preferably 550 ° C. or less. Thus, the calcination is, for example, in the range of 500 ° C to 650 ° C, preferably in the range of 550 ° C to 650 ° C, more preferably in the range of 570 ° C to 590 ° C, and even more preferably in the range of 575 ° C to 585 ° C. It is performed under a temperature having a temperature range.

  However, when the catalyst according to the invention is prepared by the above method, it is preferred that the washcoat layer not be washed after application and optional drying.

Therefore, the catalyst of the present invention is prepared by the following steps.
(A) supplying at least one zeolite selected from at least one zeolite of MFI structure type and zeolites of CHA structure type; At least a portion of the one or more zeolites of the MFI structure type includes iron and at least a portion of the one or more additional zeolites of the CHA structure type includes copper.
(B) supplying one or more washcoat compositions each containing one or more zeolites;
(C) applying one or more washcoat layers to one or more respective layers on the substrate, and a drying step is optionally performed after each application of the one or more individual layers;
(D) optionally washing and / or drying the coated substrate; the coated substrate is preferably not washed;
(E) The coated substrate is transferred to a calcination process.

Example 1
The catalyst composition contains 1.35 g / in ^{3 of} CHA structure type zeolite, which has a silica to alumina ratio (SAR) of approximately 30 and has a total mass of CHA zeolite. It contains 3% by mass of copper as a standard. The catalyst composition contains 1.35 g / in ^{3 of} MFI type zeolite, which has a silica to alumina ratio (SAR) of approximately 26, and the total mass of the MFI type zeolite. It contains 3.8% by mass of iron as a reference and has a silica alumina binder of 0.3 g / in ³ .

(Comparative Example 2)
The catalyst composition is prepared containing 1.9 g / in ^{3 of} CHA structure type zeolite. This CHA-type zeolite has a silica to alumina ratio (SAR) of approximately 30, and contains 3% by weight of copper based on the total mass of the CHA-type zeolite, and is 0.1 g / in ³ silica alumina. Has a binder.

(Comparative Example 3)
The catalyst composition was prepared containing 1.35 g / in ^{3 of} BEA type zeolite. This BEA zeolite has a silica to alumina ratio (SAR) of approximately 40 and contains 1.3 mass% iron based on the total mass of the BEA zeolite. On the other hand, the catalyst composition contains 1.35 g / in ^{3 of} MFI type zeolite, and this MFI type zeolite has a ratio of silica to alumina of about 26 and is based on the total mass of the MFI type zeolite. 3.8% by mass of iron and a silica alumina binder of 0.3 g / in ³ .

(SCR performance test)
The DeNO _x performance of the SCR catalyst was evaluated in a transient state using a New European Driving Cycle, also called MVEG (Motor Vehicle Emissions Group). In particular, in the test state, a trace amount of NO _{x in the} exhaust gas stream contained NO ₂ which was approximately 30% by mass based on the total content of NO _x .

  In the test, the catalyst compositions according to Example 1 and Comparative Examples 2 and 3 were each coated with a 5.66 "x 5.66" x 6 "flow-through honeycomb substrate. This substrate had a capacity of 2.5L. A cell density of 400 cells per square inch, and a wall thickness of approximately 100 μm (4 mm) .The catalyst samples prepared in this way are each a diesel oxidation catalyst (DOC) placed upstream of the catalyst to be tested. ) And a catalytic soot filter (CSF).

The results of the NEDC catalyst test are shown in FIGS. 1 and 2, respectively. As shown, the catalyst according to the invention according to Example 1 containing a combination of CHA type and MFI type zeolites has clearly improved properties when compared to the catalyst sample of Comparative Example 2 containing only CHA type zeolite. Show. In particular, as can be seen from FIG. 2, the catalyst according to the invention exhibits a considerably higher conversion rate of NO _x emissions than the catalyst of Comparative Example 2. Moreover, considering the results shown in Figure 1, the level of the NO _X emissions is shown as a function of NEDC test time, the catalyst according to the invention, corresponding to the previous European driving cycle (ECE-15) Compared with Comparative Example 2 between 0-800 seconds and 800-1200 seconds in extra-urban part of the driving cycle with higher space velocity and higher NO _x mass flow rate, exhibit excellent conversion characteristics did.

In contrast to the specific MFI / CHA zeolite mixture of the example according to the invention comprising an ion exchange zeolite or a mixture of MFI and BEA structure type zeolites, according to the test results of comparative example 3 in FIG. The catalyst has a slightly lower performance during the low temperature and moderate space velocity portion of the NEDC test (see FIG. 1). However, the above initial characteristics are well compensated for by significant conversion rates at higher space velocities and higher NO _x mass flow rates. Thus, as can be understood from the results of the overall characteristics shown in FIG. 2, the catalyst according to the invention exhibits characteristics superior to the catalyst according to Comparative Example 3. In particular, the characteristics of the catalyst according to Comparative Example 3 are somewhat better applied to the regenerative urban driving conditions in NEDC between 0 and 800 seconds, but the catalyst according to the invention is between 800 seconds and 1200 seconds. The remarkable characteristics in the extra-urban driving section of the present invention clearly show excellent characteristics over the entire cycle. Therefore, when considering the overall catalyst characteristics, the catalyst according to the invention takes the time of an actual motor vehicle over time when the actual driving behavior of an average passenger car as shown in the NEDC test is considered. It is well adapted to the exhaust gas emission pattern.

  As a result, the catalyst according to the invention shows clearly superior properties in SCR when compared to the prior art catalyst represented by Comparative Example 2. Furthermore, this is particularly noticeable in the actual driving conditions resulting from the use of motor vehicles, as shown in the NEDC test. In particular, such good results can be attributed to the use of specific bonds in the zeolitic material defined by the catalyst of the present invention.

Claims (17)

A catalyst suitably used for the use of selective catalytic reduction (SCR),
One or more zeolites of MFI structure type;
One or more zeolites of the CHA structure type,
A catalyst characterized in that at least part of one or more zeolites of MFI structure type contains iron (Fe) and at least part of one or more zeolites of CHA structure type contains copper (Cu).   The mass ratio of one or more zeolites of MFI structure type is in the range of 1:10 to 10: 1, preferably 1: 5 to 5: 1, more preferably, relative to one or more zeolites of CHA structure type. 1: 2 to 2: 1, more preferably 0.7: 1 to 1: 0.7, more preferably 0.8: 1 to 1: 0.8, and more preferably 0.9. The catalyst according to claim 1, wherein the catalyst is in the range of from 1: 1 to 1: 0.9.   Catalyst according to claim 1 or 2, characterized in that one or more zeolites, preferably all zeolites, contain both Al and Si in their respective zeolite structures.   In one or more zeolites of the MFI structure type, the silica to alumina molar ratio (SAR) is in the range of 5 to 150, preferably 15 to 100, more preferably 20 to 50, more preferably 23 to 30, and more The catalyst according to claim 3, more preferably in the range of 25-27.   In one or more zeolites of the CHA structure type, the silica to alumina molar ratio (SAR) is in the range of 5-100, preferably 10-70, more preferably 20-55, more preferably 25-35, The catalyst according to claim 3 or 4, more preferably in the range of 28 to 32.   The amount of Fe contained in one or more zeolites of the MFI structure type is in the range of 0.1 to 15% by mass, preferably 0.5 to 0.5% based on the mass of the one or more zeolites. The range of 10% by mass, more preferably 1.0 to 7.0% by mass, more preferably 2.5 to 5.5% by mass, more preferably 3.5 to 4.2% by mass, and more preferably. The catalyst according to any one of claims 1 to 5, wherein the catalyst is in a range of 3.7 to 4.0 mass%.   The amount of Cu contained in the one or more zeolites of the CHA structure type is in the range of 0.05 to 15% by mass based on the mass of the one or more zeolites, preferably the amount of Cu is 0.1 to 0.1%. In the range of 10% by mass, more preferably in the range of 0.5-5.0% by mass, more preferably in the range of 1.0-4.0% by mass, more preferably in the range of 1.6-3.4% by mass. The catalyst according to any one of claims 1 to 6, characterized in that it is in the range, more preferably in the range of 1.8 to 3.2% by weight.   The catalyst according to any one of claims 1 to 7, wherein the catalyst further comprises a substrate, and the substrate is preferably a honeycomb substrate coated with one or more zeolites.   The substrate is selected from the group consisting of a flow-through substrate and a wall flow substrate, the group preferably consisting of a cordierite flow-through substrate and a wall flow substrate, preferably containing zeolites in a single layer. The catalyst according to claim 8, wherein:   The catalyst contains one or more layers, which are preferably washcoat layers applied to the substrate, preferably containing one or more single layers or two or more separate layers containing zeolites, preferably The catalyst according to claim 8 or 9, wherein the zeolite is contained in a single layer. Either one or more zeolites of the MFI structure type, one or more zeolites of the CHA structure type, or both one or more zeolites of the MFI structure type and one or more zeolites of the CHA structure type, respectively loading of 1~5.0g / in ^3, preferably 0.7~2.0g / in ^3, more preferably 1.0~1.7g / in ^3, and more preferably from 1.15 to 1 0.55 g / in ³ , more preferably 1.25 to 1.45 g / in ³ , more preferably 1.32 to 1.38 g / in ³ , and even more preferably 1.34 to 1.36 g / in ³ . ^The catalyst according to claim 1, wherein the catalyst is present in the catalyst within a load amount of ³ . The catalyst is included in an exhaust gas processing system having an internal combustion engine, and an exhaust gas conduit that performs fluid communication with the internal combustion engine.
The catalyst is present in the exhaust gas conduit;
The catalyst according to any one of claims 1 to 11, wherein the internal combustion engine is preferably a lean combustion engine, more preferably a diesel engine. An exhaust gas treatment system comprising an internal combustion engine and an exhaust gas conduit for fluid communication with the internal combustion engine,
Comprising the catalyst according to any one of claims 1 to 11 in an exhaust gas conduit;
The exhaust gas treatment system is characterized in that the internal combustion engine is preferably a lean combustion engine, and more preferably a diesel engine. Further comprising an oxidation catalyst and / or a catalyst soot filter (CSF),
The oxidation catalyst and / or CSF is preferably arranged upstream of the catalyst according to any one of claims 1 to 11,
The exhaust gas treatment system according to claim 13, wherein the oxidation catalyst is a diesel oxidation catalyst when the internal combustion engine is a diesel engine. A method for treating a gas stream comprising:
The gas stream contains NO _x containing the gas stream covered and / or passed through the catalyst according to any one of claims 1 to 11;
The gas stream is preferably an exhaust gas stream, more preferably a gas stream originating from an internal combustion engine, more preferably a diesel exhaust gas stream, and a gas stream containing NO _x Processing method. The gas flow is
The method for treating a gas stream containing NO _{x according} to claim 15, comprising ammonia and / or urea. The NO ₂ content contained in the gas stream before contacting the catalyst is 80% by mass or less based on 100% by mass of NO _x , preferably the NO ₂ content is in the range of 5 to 70% by mass. More preferably, it is in the range of 10-60 mass%, more preferably 15-55 mass%, and even more preferably 20-50 mass%. _A method for treating a gas stream containing _X.

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